Light module, method for manufacturing a light module and rear view device

ABSTRACT

The present disclosure refers to a light module, comprising a lens unit, which is formed with a bottom, a lid and one or more side walls between the bottom and the lid, wherein the one or more side walls provide one or more insertion openings; a printed circuit board unit, which carries one or more light sources and is inserted into the lens unit through a first insertion opening of the one or more insertion openings such that light emitted by the one or more light sources exits the light module through the bottom and/or the lid of the lens unit; and a housing unit, which is provided with a bottom opening, a lid opening and one or more side walls between the bottom opening and the lid opening, wherein the lens unit is arranged within the housing unit such that the bottom opening of the housing unit is closed by the bottom of the lens unit, the lid opening of the housing unit is closed by the lid of the lens unit, and the one or more insertion openings of the lens unit is closed by the one or more side walls of the housing unit. It also refers to an external rear view device with such a light unit.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to German PatentApplication No. DE 10 2021 107 473.8, filed on Mar. 24, 2021, which isincorporated herein by reference in its entirety.

BACKGROUND 1. Field

The present disclosure relates to a light module, in particular adaptedfor an exterior rear view device, and an exterior rear view device for avehicle with such a light module.

2. Related Art

US 2005/0168922 A1 refers to a light module in form of an optoelectroniccomponent based on the surface mount technology, said componentcomprising a electrically conductive material, an opaque plasticmaterial, and a cavity, wherein the electrically conductive materialserves as a base for the assembly, the opaque plastic material providesa housing for the whole component, and the cavity is located within theplastic material where an optoelectronic chip is mounted in. The knownlight module provides a solderless LED holder without additionalmeasures for the attachment to a device.

EP 3 138 734 B1 discloses an exterior rear view device light assemblycomprising at least one light module for the light assembly and at leastone printed circuit board unit, with the light module comprising a lightsource unit with at least one wire for an electric connection with saidprinted circuit board unit of the light assembly, with the light sourceunit comprising a radiation surface and a light source housing, ahousing unit supporting the light source unit and being provided withconnecting and/or holding means for the attachment to at least one part,in particular a housing part, of the rear view device, and sealing meansfor water and dustproof of the connection between the light module andthe at least one part. The printed circuit board unit is remote from thelight module and the wire(s) of the light module is/are soldered to theprinted circuit board unit providing a soldering pad pattern. Thesealing means forms the perimeter of the housing unit in the regionsupporting the light source unit, and the housing unit is formedtogether with the light source housing and the sealing means by 2-Kinjection molding.

SUMMARY

It is an object of the present disclosure to provide a light assemblythat is not only is compact and easy to mount, but also easy tomanufacture and at least whether proof, preferably water proof.

This object may be achieved by a light module, comprising a lens unit,which is formed with a bottom, a lid and one or more side walls betweenthe bottom and the lid, wherein the one or more side walls provide oneor more insertion openings; a printed circuit board unit, which carriesone or more light sources and is inserted into the lens unit through afirst insertion opening of the one or more insertion openings such thatlight emitted by the one or more light sources exits the light modulethrough the bottom and/or the lid of the lens unit; and a housing unit,which is provided with a bottom opening, a lid opening and one or moreside walls between the bottom opening and the lid opening, wherein thelens unit is arranged within the housing unit such that the bottomopening of the housing unit is closed by the bottom of the lens unit,the lid opening of the housing unit is closed by the lid of the lensunit, and the one or more insertion openings of the lens unit is closedby the one or more side walls of the housing unit.

It is proposed that the printed circuit board unit is supported by thelens unit, wherein preferably two opposite edges of the printed circuitboard unit are arranged on or in two guide rails provided by the lensunit, in particular by two opposite side walls of the lens unit.

Embodiments can be further specified in that the printed circuit boardunit provides one or more connector pins and/or at least one extension,wherein preferably the one or more connector pins extend into a secondinsertion opening of the one or more insertion openings of the lens unitand/or the at least one extension extends into a third insertion openingof the one or more insertion openings of the lens unit, with inparticular the second and/or third insertion opening being provided bythe first insertion opening.

Further, embodiments can be characterized in that the housing unit isprovided with at least one stop and/or alignment feature for the lensunit and/or the printed circuit board unit, wherein preferably thehousing unit provides a first step-like extension around its bottomopening for locating the bottom of the lens unit and/or a secondstep-like extension around its lid opening for locating the lid of thelens unit and/or an internal step on the internal surface of the sidewall closing the first insertion opening of the lens unit for locatingthe at least one extension of the printed circuit board unit.

With the present disclosure it is also proposed that a first weldingtrack is provided between the housing unit and the lens unit, preferablyaround the bottom opening of the housing unit, in particular defined bya spike running parallel to the first step-like extension, and/or asecond welding track is provided between the housing unit and the lensunit, preferably around the lid opening of the housing unit, inparticular defined by a spike running along the second step-likeextension.

The first and second welding tracks may be simultaneously conducted.

It is proposed that at least one connector extension is provided by thehousing unit for inserting a connector for connecting the printedcircuit board unit, wherein preferably the at least one connectorextension is provided by the side wall closing the one or more insertionopenings of the lens unit, in particular formed on the external surfaceof the side wall in the region of the internal step, and/or whereinpreferably an isolating rack is extending in the at least one connectorextension, in particular between two connector pins of the one or moreconnector pins of the printed circuit board unit.

In addition, the one or more light sources may comprise at least two,preferably three, light source units, wherein preferably each lightsource units comprises an LED unit.

The lens unit may be formed of a clear and/or transparent plasticmaterial, and/or the housing unit may be formed of an opaque and/ornon-transparent plastic material.

It is further proposed that the housing unit is provided, in particularformed, with an attachment portion, wherein preferably the attachmentportion is adapted to mount the light unit via a clip, snap and/or latchconnection to a rear view device, and/or wherein preferably theattachment portion is provided with an attachment extension, and/orwherein preferably the attachment portion has a T-shaped cross-section.

The present disclosure also provides an external rear view device withat least one rear view element arranged in a head assembly and at leaston light unit of the present disclosure for providing a side turnindicator, a blind spot detection, a logo lamp, a door handle lightand/or an approach light.

It is also proposed that the radiation surface of the light module,preferably provided by the bottom of the lens unit, flushes with anexterior surface of the external rear view device.

Embodiments of the external rear view device of the present disclosuremay further comprise a base assembly for attachment to a vehicle,wherein the head assembly is moveable relative to the base assembly.

It is also proposed that at least one first light module is attached tothe head assembly, in particular a head frame, and/or at least onesecond light module is attached to the base assembly, wherein preferablythe attachment portion of the light module is providing a releasableclip, snap and/or latch connection.

Finally, it is proposed that a connector is entered into each connectorextension of the light module for sealing the same.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description,will be better understood when read in conjunction with the appendeddrawings. For the purpose of illustration, certain examples of thepresent disclosure are shown in the drawings. It should be understood,however, that the present disclosure is not limited to the precisearrangements and instrumentalities shown. The accompanying drawings,which are incorporated in and constitute a part of this specification,illustrate an implementation of system, apparatuses, and methodsconsistent with the present disclosure and, together with the detaileddescription, serve to explain advantages and principles consistent withthe present disclosure, wherein:

FIG. 1a is a perspective view of a lens unit of a light module of thepresent disclosure;

FIG. 1b is a further perspective view of the lens unit of FIG. 1 a;

FIG. 2 is a top view on a housing unit of the light module of thepresent invention;

FIG. 3 is a longitudinal cross-section of the light module of thepresent invention;

FIG. 4 is a perspective view of the light module of FIG. 3, with aconnector;

FIG. 5 is a perspective view of the light module of FIG. 4, mounted to ahead frame of a rear view device;

FIG. 6a is a transversal cross-section of the housing unit of FIG. 2;

FIG. 6b is a cross-section taken along the line B-B of FIG. 6 a;

FIG. 6c is an enlarged detail view of the lower end in FIG. 6b ; and

FIG. 6d is an enlarged view of the upper end of FIG. 6 b.

DETAILED DESCRIPTION

A light module 10 of the present disclosure is shown in FIG. 3 as wellas 4. Thus, the light module 10 comprises a non-transparent plastichousing unit 50 shown in FIG. 2 and a lens unit 40 made out of a crystalclear material, in particular plastic, accommodating a printed circuitboard unit 30 carrying three LED units 20, 21, 22, as shown in FIGS. 1aand 1b . Thus, FIG. 3 shows the lens unit 40 of FIGS. 1a and 1b arrangedwithin the housing unit 50 of FIG. 2.

The lens unit 40 comprises a bottom 42 acting as a light window forlight emitted by one or both of the LED units 20, 21, 22. Opposite saidbottom 42 there is a lid 44, between the bottom 42 and the lid 44 thereis at least one side wall and below the lid 44, the printed circuitboard unit 30 with the LED units 20, 21, 22 is inserted by enteringopposite edges of the printed circuit board unit 30 into two guide rails46, 48 provided by the lens unit 40. For allowing such an insertion ofthe printed circuit board unit 30 with the LED units 20, 21, 22 into thelens unit 40, the lens unit 40 is provided with at least one insertionopening 49 between its bottom 42 and lid 44 and, thus, provided by theat least one side wall, as best seen in FIG. 3. For example, the lensunit 40 may be formed with 5 three side walls between the bottom 42 andthe lid 44.

The housing unit 50 is formed with a connector extension 51 which willbe explained below. In addition, said housing unit 50 is formed with abottom opening 52, a lid opening 54 and at least one side wall therebetween. Both of these openings 52, 54 are closed as soon as the lensunit 40 is inserted into the housing unit 50. In detail, the bottom 42of the lens unit 40 closes the bottom opening 52 of the house unit 50,whereas the lid 44 of the lens unit 40 closes the lid opening 54 of thehousing unit 50 as shown in FIG. 3. Still further, the insertion opening49 of the lens unit 40 is closed by the housing unit 50, for example bythe side wall of the housing unit 50 provided with the connectorextension 51.

In order to provide a sealed light module 10, the lens unit 40 and thehousing unit 50 are connected to each other by two separate weldingtracks, as indicated in FIG. 2 by the two welding tracks 56, 58 and inFIG. 3 by the welding regions 56 a, 56 b, 58 a and 58 b. Thus, noadditional O-ring seal is needed.

In addition, a sealed connector 100 may be inserted into the connectorextension 51 as shown in FIG. 4 when mounting the light module 10 to arear view device, in particular a head frame 200 thereof, as shown inFIG. 5. The connector 100 not only serves an electrical connection oftwo connector pins 32, 34 extending from the printed circuit board unit30 and, thus, the printed circuit board unit 30 with a control unitand/or power source (not shown), via cables 110, 120, but also providesthe final sealing of the light module 10 such that all housing aperturesare closed. In fact, the connector 100 closes both, the opening of thehousing unit 50 in region of the connector extension 51 as well as theinsertion opening 49 in the region of the two connector pins 32, 34.

In addition to the two connector pins 32, 34, the printed circuit boardunit 30 is provided with an attachment extension 36, see FIGS. 1a, 1band 3. Said attachment extension 36 as well as the two connector pins32, 34 extend in the direction of the insertion opening 49, and theattachment extension 36 engages an internal step 59 of the housing unit50 extending into the interior of the housing unit 50. Thus, theattachment extension 36 and the step 59 ensure the correct location ofthe sub-assembly of the lens unit 40 together with the printed circuitboard unit 30 carrying the LED units 20, 21, 22 in the housing unit 50.

The housing 50 is also provided with an attachment portion 60, best seenin FIGS. 4 and 5. The attachment portion is provided with an attachmentsextension 61 such that its cross-section is substantially T-shaped. Theattachment portion 60 is suited for a clip connection of the lightmodule 10 to the head frame 200.

The details of the sealing provided by the two separate welding tracks56, 58 with the welding region 56 a, 56 b, 58 a, 58 b is furtherillustrated with respect to FIGS. 6a to 6 d.

FIG. 6a shows a transversal cross-section of the housing unit 50, andFIG. 6b shows the cross-section taken along the line B-B of FIG. 6a ,which goes through both of the welding tracks 54, 58. Details of thebottom welding track region 56 b are shown in FIG. 6d , and details ofthe top welding track region 56 b in FIG. 6 c.

Accordingly, the edges provided around the openings 52 and 54 of thehousing unit 50 are formed to support the bottom 42 and the lid 44 ofthe lens unit 40, respectively, and facilitate the welding for a sealingthe unit 10. For that purpose, step-like extensions 56 ba and 58 ba areprovided to embrace an edge of the bottom 42 and the lid 44,respectively. In addition spikes 56 bb and 58 bb providing the weldingtracks 56, 58 by either running parallel to the respective step-likeextension 56 ba or on the step-like extension 58 ba can be seen in FIGS.6d and 6 c.

The final light unit 10, as soon as mounted in the rear view device andconnected with the connector 100 inserted into the connector extension51, is a sealed module with the clear lens 40 letting the LED lightgoing through the lens bottom 42 and the bottom opening 54 of thehousing unit 50 respecting EC 48 regulation.

It will be appreciated by those skilled in the art that changes could bemade to the embodiments described above without departing from the broadinventive concept thereof. It is understood, therefore, that theinvention disclosed herein is not limited to the particular embodimentsdisclosed, and is intended to cover modifications within the spirit andscope of the present invention.

REFERENCE SIGNS

-   10 light module-   20 LED unit-   21 LED unit-   22 LED unit-   30 printed circuit board unit-   32 connector pin-   34 connector pin-   36 extension-   40 lens unit-   42 bottom-   44 lid-   46 guide rail-   48 guide rail-   49 insertion opening-   50 housing unit-   51 connector extension-   52 bottom opening-   54 lid opening-   56 weld track-   56 a, 56 b welding region-   56 ba step-like extension-   56 bb spike-   58 weld track-   58 a, 58 b welding region-   58 ba step-like extension-   58 bb spike-   59 internal step-   60 attachment element-   61 attachment extension-   100 connector-   110 cable-   110 cable-   200 head frame

1. A light unit, comprising a lens unit, which is formed with a bottom,a lid and one or more side walls between the bottom and the lid, whereinthe one or more side walls provide one or more insertion openings; aprinted circuit board unit, which carries one or more light sources andis inserted into the lens unit through a first insertion opening of theone or more insertion openings such that light emitted by the one ormore light sources exits the light module through the bottom and/or thelid of the lens unit; and a housing unit, which is provided with abottom opening, a lid opening and one or more side walls between thebottom opening and the lid opening, wherein the lens unit is arrangedwithin the housing unit such that the bottom opening of the housing unitis closed by the bottom of the lens unit, the lid opening of the housingunit is closed by the lid of the lens unit, and the one or moreinsertion openings of the lens unit is closed by the one or more sidewalls of the housing unit.
 2. The light unit of claim 1, wherein theprinted circuit board unit is supported by the lens unit, and twoopposite edges of the printed circuit board unit are arranged on or intwo guide rails provided by two opposite side walls of the lens unit. 3.The light unit of claim 1, wherein the printed circuit board unitprovides one or more connector pins and at least one extension, and theone or more connector pins extend into a second insertion opening of theone or more insertion openings of the lens unit and the at least oneextension extends into a third insertion opening of the one or moreinsertion openings of the lens unit, with the second and third insertionopening being provided by the first insertion opening.
 4. The light unitof claim 1, wherein the housing unit is provided with at least one stopand alignment feature for the lens unit and the printed circuit boardunit, and the housing unit provides a first step-like extension aroundits bottom opening for locating the bottom of the lens unit and a secondstep-like extension around its lid opening for locating the lid of thelens unit and an internal step on the internal surface of the side wallclosing the first insertion opening of the lens unit for locating the atleast one extension of the printed circuit board unit.
 5. The light unitof claim 1, wherein a first welding track is provided between thehousing unit and the lens unit, around the bottom opening of the housingunit, defined by a spike running parallel to the first step-likeextension, and a second welding track is provided between the housingunit and the lens unit, around the lid opening of the housing unit,defined by a spike running along the second step-like extension.
 6. Thelight unit of claim 1, wherein at least one connector extension isprovided by the housing unit for inserting a connector for connectingthe printed circuit board unit, and the at least one connector extensionis provided by the side wall closing the one or more insertion openingsof the lens unit, formed on the external surface of the side wall in theregion of the internal step, and an isolating rack is extending in theat least one connector extension, between two connector pins of the oneor more connector pins of the printed circuit board unit.
 7. The lightunit of claim 1, wherein the one or more light sources comprise at leasttwo, preferably three, light source units, wherein each light sourceunits comprises an LED unit.
 8. The light unit of claim 1, wherein thelens unit is formed of a clear and/or transparent plastic material, andthe housing unit is formed of an opaque and/or non-transparent plasticmaterial.
 9. The light unit of claim 1, wherein the housing unit isformed with an attachment portion, and the attachment portion is adaptedto mount the light unit via a clip, snap and/or latch connection to arear view device, and the attachment portion is provided with anattachment extension, and the attachment portion has a T-shapedcross-section.
 10. An external rear view device with at least one rearview element arranged in a head assembly and at least one light unit forproviding a side turn indicator, a blind spot detection, a logo lamp, adoor handle light and/or an approach light, the light unit comprising: alens unit, which is formed with a bottom, a lid and one or more sidewalls between the bottom and the lid, wherein the one or more side wallsprovide one or more insertion openings; a printed circuit board unit,which carries one or more light sources and is inserted into the lensunit through a first insertion opening of the one or more insertionopenings such that light emitted by the one or more light sources exitsthe light module through the bottom and/or the lid of the lens unit; anda housing unit, which is provided with a bottom opening, a lid openingand one or more side walls between the bottom opening and the lidopening, wherein the lens unit is arranged within the housing unit suchthat the bottom opening of the housing unit is closed by the bottom ofthe lens unit, the lid opening of the housing unit is closed by the lidof the lens unit, and the one or more insertion openings of the lensunit is closed by the one or more side walls of the housing unit. 11.The external rear view device of claim 10, wherein the radiation surfaceof the light module, provided by the bottom of the lens unit, flusheswith an exterior surface of the external rear view device.
 12. Theexternal rear view device of claim 10, further comprising a baseassembly for attachment to a vehicle, wherein the head assembly ismoveable relative to the base assembly.
 13. The external rear viewdevice of claims 10 to 12, wherein at least one first light module isattached to a head frame, at least one second light module is attachedto the base assembly, and the attachment portion of the light module isproviding a releasable clip, snap and/or latch connection.
 14. Theexternal rear view device of claim 10, wherein a connector is enteredinto each connector extension of the light module for sealing the same.